Zr-SBA-15 supported Ni catalysts for lean NOx reduction

• High Zr-loaded SBA-15 (Zr-SBA (DS–PS)) was developed by DS–PS synthesis method.
• Non-noble metal-based catalyst was developed by doping Ni on Zr-SBA (DS–PS).
• A 100% N2 yield was obtained over Zr-SBA (DS–PS)-Ni-2.5 catalyst.
• The catalyst structure was stable in the extreme prolonged reaction conditions.

An efficient C3H8–SCR catalyst with remarkable surface acidity, high surface area and high hydrothermal stability has been developed using an innovative catalyst preparation technique. In this method, a combination of direct and post-synthesis methods (DS–PS) has been employed sequentially for the preparation of a highly Zr-loaded SBA-15 (32.1 wt%). A series of novel catalysts have been developed by doping various contents of nickel on the prepared Zr-loaded support and have been used for NO reduction with propane in the presence of excess oxygen and water vapor in a fixed bed reactor. Among the various catalysts prepared, the catalyst with a nickel content of 2.5 wt% exhibited the highest activity with the ability to fully convert NO into N2 in the presence of 10% oxygen, 1750 ppm propane and 500 ppm NO at 450 °C. A satisfactory catalytic activity has been found in the presence of 7 vol% of water vapor.

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